How to Test for Vacuum or Boost Leaks - Ford Mustang Forums : Mustang Forum
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post #1 of 3 Old 10-14-2005, 09:39 PM Thread Starter
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How to Test for Vacuum or Boost Leaks

Looks pretty straight forward, I might have to build one just to have around.

How to build an Intercooler Pipe Pressure Leak Tester

Parts Needed:

A 4 inch long piece of 2.5" O.D. (outside diameter) hose. (I used some radiator hose I got at NAPA)
1.5" I.D. (inside diameter) PVC end cap.
2 band clamps that will fit around the 2.5" pipe above.
A valve stem (I used the rubber type you press in)

Note that if you have a larger turbo, the sizes of the end cap and hose may need to be larger in order to fit the turbo inlet.

Can't figure out how to post the pics so here is a link

To assemble, just put everything together as shown.

To assemble, just put everything together as shown.

To get the valve stem in, I had to drill a hole in the PVC cap.

To use it, just remove the intake pipe from your turbocharger inlet, and attach this in its' place.

Now you need to hook something up to the valve stem to pressurize the intake so you can listen for leaks. I use a 7 gallon air tank I got from Walmart, I just fill it up with air at the local gas station. You can also use a simple bike pump.

If you have a manual boost controller hooked up, you might want to plug off its' intake hose, as they leak a lot of air, making it hard to pinpoint the real leak.

Pressurize the system, and listen all over for leaks. Make sure you or a friend listens under the bumper too, wherever there is IC piping.

A leak will be obvious, they make a loud hissing sound.

You might want to have a friend check out your boost gauge while you are pressurizing things, to make sure you don't put too much pressure on things. (20 psi should be safe, or whatever you run safely for boost)

Places I have heard of leaks occuring:

BOV flange
Intake manifold ports
Throttle Body gaskets
Holes in the intercooler
Holes in the intercooler piping (sometimes the rubber pipe inside the stock woven mesh pipes cracks, and you can't see it from the outside... the pressure tester will find it though!! )

Pictures and Text by Brent Cook

Idea for tester from Josh Wingell

Contact [email protected] for questions.

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post #2 of 3 Old 10-17-2005, 04:47 AM
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great post man.........

hotwheels of

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post #3 of 3 Old 10-17-2005, 07:30 AM
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Yup made one of these for the Talon from these exact instructions.

What the instructions don't say is you need to rotate the engine to close the exhaust valves. Otherwise you'll barely build any pressure and be chasing leaks around the headers as the air escapes out the exhaust.

92 5.0 Notch - DJG, T5, Factory A/C & Radio Delete, P/S Delete, 17x8/17x9 Bullitt Wheels, Bullitt Springs, MM C/C Plates, Bilsteins
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